Process for producing frozen confectionery products

Abstract

A process for producing a frozen confectionery product is provided, the process comprising: extruding a frozen confection from a nozzle; and cutting the extruded frozen confection with an iris cutter; characterised in that the iris cutter is cooled to a temperature below 10° C. An apparatus for operating the process is also provided.

Description

TECHNICAL FIELD OF THE INVENTION[0001]The present invention relates to a hygienic process and apparatus for producing frozen confectionery products using an iris cutter.BACKGROUND TO THE INVENTION[0002]Food products consisting of a core of filling inside a coating are well known. They can be produced by co-extruding the coating and filling, and then using an iris cutter or diaphragm to encapsulate the filling within the coating as the extrudate is portioned. Such iris cutters are described in U.S. Pat. No. 4,251,201 and U.S. Pat. No. 4,734,024. They typically comprise a number of moveable blades held within a casing or tray and which form an aperture of variable size. The aperture can be opened and closed by sliding or rotating the blades. This type of process is known for encapsulating fillings in various food products, such as dough, as described for example in U.S. Pat. No. 4,734,024. More recently, it has also been applied to produce frozen confections in US 2005 / 0233033.[0003]H...

AI Technical Summary

Benefits of technology

[0007]The “temperature of the cutter” refers to the temperature of all food contacting surfaces of the cutter. The temperature of a food contacting surface is measured by fixing a thermocouple onto the surface. The cooling reduces the rate of growth of micro-organisms so that the process can be operated for extended periods of time. Preferably the cutter is maintained at a temperature below 5° C., more preferably about 0° C. The lower the temperature, the less microbial growth takes place. However, the temperature should not be too low in order to avoid frozen confection freezing between the cutter blades and hindering their motion. Preferably the cutter is maintained at a temperature above −5° C.

[0009]Preferably cooling is achieved by locating the iris cutter in a chamber through which cold gas, preferably cold air which has been filtered and dehumidified, is circulated. Preferably the cold air is at a temperature of below −5° C., such as about −7° C. or −10° C. Surprisingly we have found that this provides sufficient cooling so that the process can be operated for an extended period of time, e.g. at least 8 hours, such as 24 or 48 hours, without the need to remove or clean the cutter. This method of cooling is sufficient to counteract heat generated by friction between the blades. Using cold air has the advantage of being more controllable than other sources of cooling, such as cryogenic gases. Moreover, this method of cooling requires only simple equipment, compared e.g. to directly cooling the cutter by circulating a refrigerated liquid (e.g. glycol) through channels within the cutter.

Problems solved by technology

However, we have found that further problems arise when an iris cutter designed principally for producing products with an outer layer of dough etc. is used to manufacture products with an outer layer of a frozen confection.

Unlike the commonly used encapsulating materials, such as dough, frozen confections are liable to melt.

Friction between the blades of the iris cutter causes local heating, which can melt small amounts of frozen confection.

Although the amount of frozen confection that is melted is small, so that the shape of the products is not noticeably affected, it can cause other problems.

In particular, in a factory situation, it may not be possible to clean or replace the cutter during a production run of several hours or more.

This can result in potential problems due to growth of micro-organisms on the residue of melted frozen confection which could contaminate the products.

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